Optimizing control systems

ABSTRACT

Orthogonal Modulations of process control variables produces modulation of a performance indicating signal. This performance indicating signal is processed to generate a plurality of control signals indicative of direction and magnitude of change of a process control variable toward obtaining optimum performance. Each control signal results from multiplying the performance indicating signal by its respective modulation signal followed by integration and a sample and hold circuit. Primary control signals may be imposed on the process control with the optimumly controlled variables interacting with such primary control through process interactions. The integrated control signals are sampled during time periods small with respect to the shortest time period of the orthogonal modulation. The process control permits the process being controlled to settle down after each optimum control period. Adaptive feedforward techniques are described. Phase reversal of modulation between successive measurements improves noise immunity. Random noise modulation of frequency of modulation and phase reversals also increases noise immunity.

United States Patent [72] Inventor Lawrence R. Smith Phoenix, Ariz. 211 Appl. No. 819,877 [22] Filed Apr. 28, 1969 [45] Patented Nov. 2, 1971 [73] Assignee Motorola, Inc.

Franklin Park, Ill. Continuation-impart of application Ser. No. 7 70,284, Oct. 24, 1968, now abandoned. This application Apr. 28, 1969, Ser. No. 819,877

[54] OPTIMIZING CONTROL SYSTEMS 46 Claims, 23 Drawing Figs.

[52] U.S.Cl. 235/15l.l, 235/150.l, 162/262 [51] Int. Cl ..G05b13/02 [50] Field ofSearch 235/150.l, 151.1, 151.11; 318/561 [56] References Cited UNlTED STATES PATENTS 3,428,791 2/1969 Chandos 235/l5l.l 3,466,430 9/1969 Hardaway 235/150.l

OTHER REFERENCES Korn et al., Electronic Analog and Hybrid Computers, N.Y., McGraw-l-lill, 1964, p. 524-525 QA76.4 K67 Primary Examiner-Eugene G. Botz Att0rney-Mueller and Aichele ABSTRACT: Orthogonal Modulations of process control variables produces modulation of a performance indicating signal. This performance indicating signal is processed to generate a plurality of control signals indicative of direction and magnitude of change of a process control variable toward obtaining optimum performance. Each control signal results from multiplying the performance indicating signal by its respective modulation signal followed by integration and a sample and hold circuit. Primary control signals may be imposed on the process control with the optimumly controlled variables interacting with such primary control through process interactions. The integrated control signals are sampled during time periods small with respect to the shortest time period of the orthogonal modulation. The process control permits the process being controlled to settle down after each optimum control period. Adaptive feedforward techniques are described. Phase reversal of modulation between successive measurements improves noise immunity. Random noise modulation of frequency of modulation and phase reversals also increases noise immunity.

PROCESS PERFORMANCE EVALUATION COMPUTER FIG. 5)

-49 PRIMARY RESET To, p. MEAsuREIIIErIrs'YJ 4a MEMORY A? 55 ganmzme 55g ONTROL SIGNAL l m L CLOCK s 32 II3- r w AND Psmoo sleuAt se gg g ,.III lll E I'EEJE Proms I 321 l ICONTROL CHANNEL 1 I ,1? i a a 0 31 I 7 "1+3 K I l g t UNCONTROLLEO VARIABLES l l l I I ea I l I.- no I i r50 I o-h CONTROL 1 CHANNEL SET Pom'rs I K I I i l I I I I l I I I I l I l 5| I I I I I I l I OPTIMIZING CONTROLLER PAIENIEDIIUIZ I97! [3,617,717 SHEET UEUF I5 FIG. 2 LEGEND P PERFORMANCE INOIcATI G E] LINEAR MIxER SIGNAL I G) ANALOG CONTROLLER OPTIMUM PERFORMANCE S |ND|CAT|NG -g OPERATIONAL DIFFERENTIAL AMPLIFIER OPTIMIzING CONTROL X SIGNAL INTEGRATOR D PRIORITY WEIGHTING SAMPLE-AND-HOLD FACTOR cIRcuIT MAXIMUM NUMBER OF El PULSE ATE J CONTROLLED INPUT I SIGNALS MAXIMUM NUMBER AT INPUT VARIABLE CABLE WITH N SIGNAL QUANTITIES PATHS, I I

MODULATOR El ANALOG GATE I PERIOD SIGNAL 59 To STROBE 58 COMPUTER PULSES (FIG. 5)

88 xI 278 G T MOOuLATION I 277B 3, X2

I h, MODULATION 275 270 280 FREQUENCY Q .I. MONO PuLSE CONTROL 272 273 STABLE cOuNTER I 27I 27s 28' 7 RESET INVIJNTQR.

LAwRENcE RA SMITH 072M, QM {W ATTORNEYS PATENT Ell-Roy 2 I97! sum 030F715 W IILILIIIIJIII ILIL'IIILIIJILIH IOSM DZIIJL uLnn 11m ILIIL FIG. 4-

.P'ERIOD- SIGNAL I v L A0 G8 N N OT UL G OLL AU HUM GP D mom OMS I27 HIGH LIMIT I23 I L {OUT OF BOUNDS DETECTOR v FIG.- 6

PROCESS VARIABLE OR. INDIVIDUAL PERFORMANCE INVI-IN'IUR.

LAWRENCE R. SMITH FIG.- ,3

ATTORNEYS PATENTEUNUVE JOFPZOQO PAIENTEUuuv 2 I97! SHEET CBUF 15 DIFFERENTIAL PRESSURE TRANSMITTER FLOW RATE o A 4/09 SENSOR AND E DP I TRANSMITTER v 420 FLO 403 A 407 ig! FT L PUMP l 400 40') 2 428' 42 '42| SET 433 SPEED A POINT CONTROL fi PUMP g A 430 N SIGNAL 423 421 MULTIPLIER c 4|2 4'4 J DIVIDER 5E FUEL FUEL\ M SOURCE I vs K402 r TEMPERATURE-\425 TORQUE 416 434 6 4 SPEED SPEED AUXILIARY r CONTROL SIGNAL SELF-OPTIMIZING PERFORMANCE A EFFICIENCY CONTROLLER 4n INVENTOR.

LAWRENCE R. SMITH BY W Qwwfl Km ATTORNEYS PATENTEUIII'II 2 l9?! 3,617, 717

' SHEET 07 [1F 15' PROBABILITY PROBAIBILITY RANDOM NoIsE v NoIsE I -ERROR 5 +ERR0R ERRoR I) +ERROR FIG. 11 FIG. K)

I HOLD I DECISION HOLD DECISION I 456A 456A 455A v Pu) GATE 336 457A "I |1| GATE 337- \m T|ME FIG. 12

SUMMING NETWORK 593 ADAPTIVE ADAPTIVE LINEAR E LINEAR MODEL MODEL (FIG. l8) (FIG. l8)

F519 T -IOI 275 N2 wI XI w2 x2 CLOCK PULSES LAWRENCE R. SMITH ATTORNEYS PATENTEDHBV 2 7 Ian R 3,617,717

SHEET 09 HF 15 493 I 499 oac|s|on HOLD DECISION Hou: COUNTER fl'AGE 485 L SIGNAL STATE I PERIOD snenm. I 5o| x2 REVERSED moouumon m REVERSED MODULATION XI SAWLE m mu 4m' IA are SAMPLE llll ml IIIL/ un n x2 SAMPLE Jul m| IDEALIZED SIGNALS SHOWING PHASE'REVERSED 'MODULATION FIG I4 658 r' "l 656 i U sec I 6514 652 e59 ORP SET Pom K 6 51 680 v I ORP SIGNAL j L JASBI 655 665 4; sea

o CIRCUIT I80 (FIG. 5)

ABSOLUTE OUTPUT ERROR COMPUTER I INVIJNTOR.

, LAWRENCE R. SMITH DY 777%, am, 6 73mm ATTORNEYS PATENTEIIIIBV 2 I97| 3,617. 71 7 SHEET 13 or .15

Gel 692' 693 e91 699 WET DRIED PAPER MT FT VT DRYER PAPER 690 FLOW A RESIDUAL r- MIOSTURE; RATE VELOCITY MOISTURE M+3" M+4" M+5" s94 -s95 696 I I I I I -38 I ANALOG X4 l I V DELAY l NETWORK 724 l PROCESS 72I I I CONTROL 748? f I MODEL LEAD-LAG x3 I NETWORK I (FIG 2|) 722 i l ./737 I 720 I I z l 718 M9 I ADAPTIVE ADAPTIVE I LINEAR LINEAR l w l MODEL MODEL W2 I I (FIG. I8) '(FIG. I8) I I I 275 n2" x2 IoI-xI J 55 J 46 5e; l 47 I CLOCK AND 58 SELF-OPTIMIZING j 'g ggaii MODULATION PERFORMANCE v COMPUTER SOURCE so CONTROLLER (FIG 5) OTHER INPUTS FIG. 20

INVIfNTOR.

LAWRENCE R. SMITH ATTORNEYS Pmmm 2 :97: 3,617,717

SHEET 1 4 DF 1 5 UNIJUNCTION OSCILLATOR v 734 x3 A vco R2 745 732 m 743 I J 1\ V RI 746 MA FROM SUMMER 720 737 My v 742\ ANALOG F DELAY 748 NETWORK LEAD-LAG NETWORK 72 l FIG. 211

Q 7 LEAD c2 H 'l 2 E 1 Q l I I l l E RI 1 l 1 2 FREQUENCY v LEAD-LAG CHARACTERISTICS INVIJNTOR.

LAWRENCE R. SMITH ATTORNEYS OPTIMIZING CONTROL SYSTEMS RELATED APPLICATIONS This application is a continuation-in-part of application Ser. No. 770,284, filed Oct. 24, 1968 (Group 236), now abandoned.

An analog memory system referred to in the specification of this application is described in detail in Ser. No. 702,440 filed Feb. 1, 1968, in the name of the present applicant.

A control channel circuit is described in application Ser. No. 770,288, filed Oct. 24, 1968, in the name of the present applicant.

BACKGROUND OF THE. INVENTION This invention relates to supervisory control systems, particularly to those of the adaptive-control type, i.e., control systems for optimizing performance of a process toward a given performance criterion or objective.

The history of analog control, dating from the flyball governors on 18th century steam engines to the industrial threemode controllers of the l930s, has been concentrated on the stability of single control loops. By contrast, unit processes used in modern refineries and chemical processing plants involve several control loops. Modern economic conditions dictate a multidimensional control-approach to these processes where emphasis is on optimizing the overall performance by interrelating existing control loops.

Optimization is defined as a technique which varies controlled variables for maximizing or. minimizing a performance criterion, deemed necessary through changes in four major categories:

I. Environment-variations in ambient conditions (e.g.,

weather) that affect pressure", temperature, etc., so.

changing compressor capacities, heat exchange rates in air and water coolers, etc.

2. Plant/Process-variations in flow dynamics due to coking of lines, changes in catalyst activity with respect to time, heat exchange rates due to fuel quality, steam pressure, etc.

. Process Fluid-variations in feed characteristics, molecular makeup, heat content, flow rates, etc.

Economics-variations in costs of feedstock, steam, fuel,

etc.

A straightforward analysis of the process being controlled determines the dependent manipulated variables that have a dominant effect on the performance criterion or objective. Also, operating constraints can readily be established where limiting bounds are necessary to maintain safe or desired operating conditions. The optimizingfunction is to find the optimum values of the manipulated or controlled variables that best satisfy the performance criterion withinsuch operating constraints.

ln manually controlled systems, fcontrol room operators spend many hours adjusting controller set points and noting the resultant effect on process performance. The variables were merely regulated" irrespective of optimizing process performance and optimization,if performed, was performed by the operators. That is, in such manual systems the process fundamental variables such as fiow, pressure, temperature, level, etc., are controlled at set points established by manual adjustment. These variables are described as regulated or controlled variables. When the term regulated is used, it means that the variables are held-at a preset level relatively independent of process disturbances and of variations in each of the other regulated variables. A process is not truly optimized by simply regulating the process variables. One of the primary reasons for regulating the variables is to make them independent of each other so as to be readily adjustable to levels of operation necessary to obtain satisfactory performance.

Unfortunately, the problem of optimization (i.e., making a product to specification at maximum profit) is often a relatively complex function of the various independent regulated variables. The necessity of also operating the plant within safe bounds further complicates the total performance or optimization problem. Such restrictions are termed constraints" on process performance. Still further complications in optimizing process operation are created by uncontrolled variables such as inputs to theprocess that are changing with time which may modify the complex relationship of the various independently controlled variables for optimum operation.

In recent years the application of digital computing machines has focused attention to the automatic optimization of analog control loops in systems referred to as supervisory control systems. These digital computer systems attempted to provide some adaptation to process conditions of the supervisory control system.

In optimizing performance of a process, economic factors can be made as the overriding consideration. This approach results in economic benefits suchas:

1. Higher Profits-increased yielddue to reduction of offspec material.

2. Controlled Quality-product meets spec within closer tolerance.

3. Utilities Costs-lower due to better utilization.

4. Labor Costs-lower due to increased efficiency.

5. Less Downtime-in changing productquality grades.

In assessing the total economic incentives for improved control, it is necessary to balance the above listagainst the capital costs of installing the multidisciplined control system. The lower the cost ofsuch a control system and its installation, the sooner an optimizing control can be used to advantage.

A given process can be analyzed to determine a given process objective, i.e., minimum cost of operation, maximum profit from product produced, and the like.

The values of the independent regulated variables to minimize the total cost of operation or accomplish another performance objective change with time. This changing requirement results from. changes in uncontrolled variables, such, as ambient temperature, process input, aging of the process, etc. Because of these changes with time it is quite dif ficult, if not impossible, for a human operator to adjust the regulated variables to maintain optimum performance. This difiiculty is increased when the operator is restricted to very small changes (large changescan disrupt operation particularly when large changes degrade performance). The difficulty is perhaps the greatest on processes with long response times because operators do not have the ability nor patience to appropriately make small changes separated by long time inter vals. A control system that automatically adjusts the independent regulated variables to minimize thetotal cost of operation and maintains, this. minimum cost or that rapidly reestablishes optimum operation after a severe upset or change in operation is desired. Such a control system is termed an adaptive control system," an optimizing control system and the like.

During such adaptive optimizing control, the dollar expenditure should be minimized which means, that the cost of operation should be reduced as rapidly as possible. Further process operation should be such as to minimize the uncertainty of process performance about the optimum point, i.e., be operated in a stable manner at optimum. It is extremely desirable that any errors be as small as possible. This stability factor means that the system should reach optimum in a well damped manner.

The system should be designed such that the action of optimizing does not amplify or make worse upset conditionswith resulting large changes in regulated variables. An operator will recognize abnormal conditions and will wait for these conditions to subside prior to exercising manual optimization. The same procedure should be followed in automatic optimization of process performance.

Most processes generate noise or receive noise from external sources which may interfere with the control of such processes. The process noises are not always random. For example, noise from 60 cycle power lines, rotating electric machines, natural resonances of actuators, sensors or other process related equipment are capable of generating noise having periodic characteristics. The amplitude of such noise may be as large, if not larger, than the modulation of the controlled variable as effected by a process control system. If the periodicity of such periodic noise is harmonically related to the modulation period, such noise produces errors in the generation of control signals. This error appears in the gradient of any optimizing action of an optimizing control system which utilizes periodic modulation, as taught by the present invention.

If the periodicity of the noise is nearly harmonically related to the modulation of the variables, the error introduced into the control of the process can also be serious. In this latter situation, such resulting errors in the control signals can slowly change from positive to negative and then alternate therebetween for generating a beat modulation of the variable being controlled. Such action can result in an undesirable periodic wandering or deviation of the controlled variable from the optimum or desired operating point which is not compensable by many process control systems. This type of error is more serious than that which may be caused by a random noise. Random noise will cause a controlled variable and, therefore, process performance to deviate from optimum or desired operating point on a statistical basis. It is very desirable that the standard deviation of the distribution of the controlled variables from their optimum or mean value be minimized.

Process noise can contain a periodic signal of very low-fundamental frequency. In those processes wherein the performance being optimized is periodically adjusted or reset to zero, this noise becomes periodic, with a fundamental frequency determined by the periodicity of such adjustment. Such noise is synchronous or approximately synchronous with the modulation of the controlled variables. This undesired action can occur in the practice of certain aspects of the present invention and of other process control systems using periodic adjustments of the performance variables. This self-generated synchronous noise can produce errors in the calculations of the gradients utilized to control the process. Such a selfgenerated synchronous noise can result wherein there is a random upset which requires a relatively large change in the controlled variables. Such is not an unusual situation and therefore should be considered in the design and fabrication of process control systems. Such random upsets may introduce a transient into the process that causes the performance of the process to continue to change during a plurality of subsequent periodic measurement and decision cycles which are used to adjust the various controlled variables in the process. The periodic adjustment of the performance signal can produce synchronous noise and its effect can produce an error that results in an additional transient that can produce further error and resulting transient and cause changes in controlled variables in the same direction as caused by the original upset or disturbance. This cumulative effect may continue and a runaway condition will result until random noise by chance reverses its effect on the controlled variables. The net result may be that there is random cycling of the controlled variables resulting in the process control actually introducing additional variations from the desired operating point or optimum operating point. it is desired to have a process control system which will compensate for such errors and eliminate the accumulation of such errors.

Noise received from external sources can produce a similar effect as that just described for low-frequency periodic noise beats with the modulation frequency. For example, a performance continuously changing in the same direction, i.e., commonly referred to as ramping, is converted to a synchronous or approximately synchronous noise signal by the periodic adjustment of the performance signal which can cause degradation of process performance. Such ramping noise may be introduced by temperature changes or by process changes from previous adjustments of controlled variables which produce noise within the process resulting in errors in calculations of the process control system. Errors in the calculations of the control signals for these controlled variables having the lowest frequency of modulation are more susceptible to such ramping noise.

Some processes are characterized by a so-called dead-time and by large variations of material qualities that enter the process at its input. Such a situation can be effectively controlled only with feed-forward techniques. In the past, disadvantages of feed-forward control techniques included the necessity to determine and know the relationship of the optimum process control strategy to the measurement of the material qualities at the process input. Such disadvantage can be eliminated if adaptive feed-forward techniques that automatically determine the above control strategy are used. Bleaching, chemical blending, drying and others are a few examples of processes where improved control can be obtained by utilization of more than a single measurement of the quality of the process input, i.e., that measurements of quality of the materials to be processed in a bleaching operation. For example, these measurements at the process input can include measurements of flow rate, consistency, brightness, electrical conductivity and temperature of the material. These measurements made at process input can be readily made available for feeding forward to control the flow rate of a bleaching agent. In this particular example, consistency and measurement can usually be adequately controlled at a constant value. This regulation of temperature and consistency still leaves the remaining variables of flow rate, brightness and electrical conductivity to be fed forward for the control of the bleaching agent.

SUMMARY OF THE INVENTION It is an object of this invention to provide a self-optimizing process control system wherein the speed of response can be altered in a facile manner without altering the gain of the system.

It is another object of this invention to provide a selfoptimizing adaptive type of process control system which may be utilized by simple components with a wide variety of possible connections.

It is another object of this invention to optimally control a process in accordance with plural variables which are to be optimized and the optimization being derived through a single process performance indicating signal.

Another object is the minimization of the effect of noise on an optimizing control system.

Another object is to minimize initial tuning requirements of a control system. Tuning is simple and straight-forward.

Yet another object is to enable a process control system to ignore undue process upsets and yet take rapid optimization action upon the subsiding of such undue upset.

Another object is to provide adaptive feed forward in a process control system.

A feature of the invention is the provision in a control system of a single performance indicating signal derived from a plurality of measured variables to be manipulated with orthogonal modulations for the generation of plural control signals respectively modulated by the same orthogonal modulations.

A feature of the present invention is the utilization of plural orthogonally modulated or dithered" control signals to effect a control function based upon a gradient of system response to such modulated control signals.

Another feature is the utilization in a control system of plural modulated control signals having a relatively small modulation such that a system nonlinear response permits linear changing of an input variable which after successive linear approximations still can approximate a nonlinear-function. A principle involved in this feature is that principle forming the basis of the integral calculus. This feature of small modulation amplitudes further reduces the effect of this modulation on process performance.

Anotherfeature of the invention is the provision in a control system of modulated control signals wherein the frequency of such" modulation can be changed :to adjust the speed of response of such control system without altering the. gain of the system and'without modifying the system components. Integrations of the modulated signals and of a performance indicating signal from which the control signals are generated is performed on a time sampling basis with respect. to each modulation cycle; such time sampling period is small with respect to theperiod of one modulation cycle.

Another feature of the present invention is the utilization of orthogonal (including quadrature) 'modulation of control signals for making the response of a given control signal to a variationin the system performance indicated by a single perfon'nance indicating signal independent of the response of the system to other orthogonally modulated control signals. The orthogonal modulation is selected such that over a finite period of time the integration of 'theproduct of any two different modulation signals is zero, but over this same time period the integration of the product of .any one modulation signal times itself is unity. in other words, the effect of the variables on the performance of the system being optimized is separated by the use of orthogonal modulation of variables respectively controlled by respective control signals. Such separation permits simultaneous but separate control to be effected wherein the interaction within the system being controlled is considered in effecting such control actions.

Another feature is to permit the delayof integration or permit the spacing of optimizing procedures such that the control system may be permitted to hold operational'status of the control signals without optimizing action.

Another feature is the modulation of a control signal which is derived from a feed-forward control signal combined with another control signal to effect optimization of a controlled variable associated with the second control signal.

Another-feature-is the optimization of a process of the type.

described wherein some of the controlled variables are not modulated but have an association with modulated controlled variables in a manner thatthe process is still optimized, through interaction of all variables in the process being controlled.

Another feature is the provision in a process control system of an optimum range of 'operationfor. each variable in a set of variables and the removal of the effect of a measurement of'a variable when in such optimum range from the generation of control signals.

A feature corollary to the immediately preceding featureis.

that when a control variable is but of bounds-of a defined range of optimum operation, it then exerts a definite influence on the generation of control signals, not only the control signal directly associated with the measured variable, but control signals for other variables as well. Such influence is throughinteraction within the process being controlled.

A feature in conjunction with the preceding feature-is a set of plural overlapping optimum operating. ranges for a given variable. When operated in a first range, a first optimization is obtained; and when operating withina second range, a second optimum operation is obtained. The arrangement is such that when operating in the secondrangegthe. effect of measurements of such variable in adjusting system operation is determined only by the first optimum operation range characteristic. However, when the variable is out of range forboth the first and second ranges, both ranges shall haveaneffect on the generation of a performance indicating signal for quickly Another feature of the present. invention is the-randomnoise or pseudo-noise modulation of .the frequency of the modulation of the controlled variables for increasing the insensitivity of the process control-system to noise.

Another. feature is the random-noise or pseudo-noise modulation of the periodicity of the decision periods to increase the immunity of the process control system to noise.

Another feature is the utilization of feed-forward techniques which are adaptively controlled to control -a process in a self-optimizing manner.

Another feature is the utilization of phase reversals of modulation to increase immunity of the process control system to noise.

Another feature is the ability of a process-control system to selectively, delay measurement by selective amounts without the introduction of errors in the calculationsof gradients utilized for the selfloptimization of process control. The delays can provide time for the process to settle after a given decision or adjusted cycles for reducing the effect ofsynchronous noise introducedinto the process from the adjustment of the con trolled variables resulting from the decision cycle.

Another feature is the utilization of an asymmetrical modulation for cancelling the effects of synchronous or near synchronous noise onthe process beingcontrolled.

Another featureofthe-present invention is the interposition of a process model. between a self-optimizing performance controllerand theprocess being controlled. Such interposition gives additional degreesof freedom in exercising control over the process; The controller cooperates with the model of the process to effect an adaptive seltioptimizing control thereover. Delays inthe process may be incorporated into the model.

A control system utilizing the present invention for controlling a plant, process or other controlled system (hereinafter collectivelyreferred to as process) has a plurality-of sensing devices for making measurements of the performance of the controlled process. A process includes any chemical, electrical, mechanical action in combination thereof or'otheraction whichmay be controlled to effect asupplies a control signal to the process for controlling at least.

one-variable. The. measurements may include variables. that are not directly; controlled.

Thecontrol signals are continuously modulated such that the performanceofthesystem with respect to each .variable varies suchthat a gradient of performance inaccordance with the modulation is provided with control over the processbeing effected on that basis. The modulation signals for the respective variablesiarelorthogonal such-as to remove interaction between the modulation signals such that each control channel is uniquely responsive to the single performance indicating.

signal as his effected only by the variable. being controlled.

The single performance indicating signal may consist of two complementary analog or digital signals. Such a control system accounts for interactions of the variables in the process being controlled.

A- process is controlled on a cyclic basis- During each repeated control or decision period there is. a holding period during which the process is not being optimized and an optimizing period during which control functions are analyzed and modified as necessary. The holdingperiod permits the process to more or less settle down from apreceding optimizing period. During the holding period, the performance indicating signal is automatically zero adjusted to a reference value such as to assure that this signal is in the center of the linear range of its associated circuit. The control signal amplitudes are still modulated during the holding period.

The control channels each have integrators that integrate a product of the performance indicating signal with sets of strobe pulses which are gated by the respective orthogonal modulation signals. In this manner, a long time constant is provided in the integration functions. The period of sampling is short with respect to the period of l cycle of modulation. In accordance therewith the frequency of the orthogonal modulation signals may be altered without affecting the integration function and, therefore, without affecting gain of the control system. This fact means the speed of response may be altered by altering modulation frequency while process stability tends to remain high because gain is not affected.

Some of the controls in the process need not be modulated as above described. Such controls are constraints on the process. Plural controllers or other types of controlling devices may be utilized to control primary variables which are measured and the measurement supplied to the evaluation computer. The desired set point is optimized and the variables controlled by the controllers that do not have the modulation are also optimized through the interactions of the various variables in the process being controlled.

For the present system to be advantageously practiced there should be at least two variables and one constraint for a given performance objective or criterion. The relationship of the two controlled variables is then optimized to such performance objective. Additional constraints may be added on system performance. Optimization then is performed within those constraints. If the constraints are designed such that true optimum operation of the process is inhibited, the optimizing system causes operation of the process as close as permitted by the given constraints to the ultimate optimal operation as defined in the process performance of the evaluation computer or in its programming.

Another feature is the provision in a process control system of disabling all control actions upon the detection of a predetermined upset within the process being controlled. The inhibition of optimization may continue until the upset subsides, i.e., reaches a threshold upon which optimization of the process is reestablished. During the inhibition period the process control signals are maintained at the values existing just prior to the upset being detected. If the upset occurs during an optimization period, the effect of the first portion of the optimization period is erased and the process is then controlled as if the optimization period had never begun.

Additionally, the system provides for optimum filtering of the performance signal being accomplished simultaneously with changes in timing adjustment. The measurements of the system are delayed after each optimization decision to accommodate dynamics of the system such that false decisions do not result. This arrangement permits the system and the process to take relatively large process optimization steps when being operated distant from optimum without the introduction of errors on subsequent optimization steps.

Automatic zero adjustment permits large DC amplification of performance signals at any point within its input range without danger of saturation. This arrangement also eliminates slow thermal drift.

One or more of the variables within the system may be switched to manual or internal control and the process control system will then control the process to seek the optimum condition of the remaining variables with the manually or internally set point of variables being a constraint on the optimization of the process being controlled.

The process control system of the present invention may be utilized by adding to an existing control system. The standard controllers may be operated or actuated by the optimizing control system; i.e., the optimizing control system of this invention is utilized to supply set point signals to existing controllers in a process control system. This facilitates changing an existing process to be controlled by an optimizing control system.

The optimization can be cascaded, i.e., pyramided for plural optimization systems. In other words, four minor processes can be independently optimized. The four systems operating as a unit can then be optimized. For this purpose, the modulation signals for optimizing the four minor processes and the four processes taken as a whole are synchronized by an external instrument to prevent beat frequencies from affecting control of any of the processes. Also, provisions can be made for bumpless transfer from optimization control to external set point or to manual control or vice versa.

For noise immunity a clock and modulation source may be utilized which selectively reverses the phase of the modulation of the controlled variables. Such reversal may be in successive decision and holding cycles or may be generated by a random noise generator such that the reversals are in a pure random or pseudo-noise random manner. Further, the frequency of the oscillator driving the clock generator can be driven in turn by a random or pseudo-noise generator for altering the frequency of modulation in a random manner.

A process control model consisting of adaptive linear models which are summed together is interposed between a self-optimizing performance controller and a process being controlled. The process control model receives input signals representative of uncontrolled variables as well as performance indicating signals. The modulated set point or control signals from the self-optimizing perfonnance controller are combined with the other received signals to generate a control signal directed to a controlling device for controlling the process; such generated signal may be a set point signal or a conventional controller. Such controls may be cascaded, i.e., a controller may generate a set point signal for a second controller which in turn supplies a control signal to the process control model. The process performance computer receives a performance associated with each of the two cascaded controllers for optimizing the process control model in accordance therewith. The adaptive linear models can be clocked with the same modulation utilized to modulate the controlled variables. The process control model may utilize analog delay networks for delaying the adaptively and modulated control signals in accordance with delays in the process being controlled. Lead and lag relationships may also be established within the process control model.

THE DRAWING FIG. 1 is a simplified block diagram of a system illustrating a utilization of the present invention.

FIG. 2 is a legend identifying the various symbols used in the drawing.

FIG. 3 is a graphical illustration of a process performance response characteristic showing the effects of dithering or modulation of a controlled variable on process performance.

FIG. 4 is a timing diagram illustrating the operation of the present invention as shown in FIGS. 1 and 9.

FIG. 5 is a combined block schematic diagram of a process performance evaluation computer utilizable with the FIGS. 1 and 9 embodiments.

FIG. 6 is a schematic diagram of an out-of-bounds detector used in the FIG. 5 illustrated computer.

FIG. 7 is a block or signal flow diagram of a clock and modulation source usable with the FIGS. 1 and 9 illustrated embodiments.

FIG. 8 is a schematic diagram of a control channel used in the FIG. 1 embodiment.

FIG. 9 is a schematic diagram of a pumping station which has its operation optimized to efficiency with a constraint of constant flow rate and which utilizes teachings of the present invention.

FIG. 10 is a graphical representation of two probability curves showing the effect of random and periodic noise on errors in a process being controlled.

FIG. 11 is a graphical representation of the variation of probability of the effect of noise on a process derived by combining the two curves of FIG. 10 to show the effect of random 

1. A process control system for controlling a process toward a defined optimum condition, the improvement including the combination, means, including sensing means, for generating measurement signals indicative of measurements made by such sensing means for indicating performances of said process caused by variations in plural variables of such process, computer means receivIng said signals and having programming therein including performance criteria which are compared with said signals and are utilized in the computer for generating a single total performance signal indicative of all such comparisons, and means responsive to said total performance indicating signal for generating signals having opposite polarities but equal amplitudes and being indicative of said total performance signal, clock and modulation source means generating a plurality of orthogonal modulation signals alternating between first and second signal states and each having a given phase, and a period signal, there being one orthogonal modulation signal each for each variable to be optimumly controlled, and a plurality of control channels, one control channel each for each variable to be optimumly controlled and receiving one of said orthogonal modulation signals and supplying modulated control signals respectively by said orthogonal modulation signals for said process being controlled for effecting optimum operation thereof, all of said control channels receiving both said opposite polarity signals, gating means in each said control channels for gating on a time sampled basis said opposite polarity signals with said respective orthogonal modulations and said control channel having integration means for integrating results of said gating for supplying a control signal in accordance with said opposite polarity signals changing in accordance with process performance variation caused by the respective orthogonally modulated variable, and said control channels and said computer being responsive to said period signal to perform changes in said modulated control signals over repetitive finite time intervals and having alternating intervals in which the amplitude of said control signals is maintained, said computer being responsive to said period signal to generate said total performance indicating signal for indicating optimum operation during said alternating intervals and during periods in which said control signals are to be changed said total performance indicating signal indicating the actual performance of said process being controlled.
 2. The process control system of claim 1 further including a controller for being operatively associated with said process to receive a signal indicating measurement of a performance and compares such measurement signal with a set point to supply a signal indicative of such comparison, and means jointly responsive to one of said control channel supplied control signals and said controller supplied signal to generate another control signal for controlling a variable in said process.
 3. The process control system of claim 1 wherein one of said control channels includes auxiliary control signal means including means for receiving a signal, means jointly responsive to said received signal and to a control signal generated by said control channel in response to said opposite polarity signals to generate another control signal for said process.
 4. The process control system of claim 1 further including, controller means operatively associated with said process for receiving a performance indicating measurement signal and operative to compare said performance indicating measurement signal with a set point for supplying an analog control signal to said process for controlling a variable therein that has an effect on the given performance indicated by said performance indicating measurement signal, certain other variables in said process affecting said given performance, some of said other variables being controlled by plural ones of said control channels such that said process performance is optimized as to said other variables to said given performance within a constraint on optimization effected by said controller means.
 5. The process control system of claim 1 wherein said computer established performance criteria has an upper and lower bound, said computer being responsive to said measurement sigNals having values within said bounds, respectively, for effectively disconnecting such measurement signals from affecting calculation of said total performance signal and further responsive to such measurement signals when out of said respective bounds to include such value in generation of said total performance signal.
 6. The process control system of claim 1 wherein said orthogonal modulation signals continuously modulate said control signals supplied by said respective control channels irrespective of an action or inaction of said control channels with respect to the optimization of said process and said clock and modulation source means further generating clock pulses having a pulse repetitive frequency greater than any frequency of said modulation signals, said modulation signals each having first and second alternately occurring signal states, and means for combining said clock pulses and said modulation signals for supplying first and second bursts of said clock pulses respectively corresponding to said first and second signal states for each of said modulation signals.
 7. The process control system of claim 1 wherein the duration of said time sampling for said integration is short with respect to duration of any cycle of said orthogonal modulation signal used to modulate the control signal in the respective control channel such that the frequency of modulation may be altered without affecting integration time and thereby not affecting the gain of such respective control channel.
 8. The process control system of claim 1 wherein said duration of said time sampling is short with respect to duration of any cycle of any of said orthogonal modulation signals used in such systems.
 9. The process control system of claim 1 wherein said computer has a process condition detection means and being responsive to detection of a given process performance condition to inhibit all actions of said control channels tending to change values of the respective control signals as long as said given condition exists.
 10. The process control system of claim 9 wherein said process condition detection means is responsive to said total performance indicating signal exceeding a predetermined amplitude to inhibit action of said control channels.
 11. The process control system of claim 1 wherein said modulation signal for each of said control channels consists of complementary rectangular signals, one of said complementary rectangular signals gating to said integration means one of said opposite polarity signals only during one-half cycle of every cycle thereof and the complementary modulation signal other than said one complementary modulation signal gating to said integration means only during half-cycles of each cycle other than said one-half cycles.
 12. The process control system of claim 1 wherein said control channel includes gating means jointly responsive to the modulation signal modulating the control signal thereof for successively gating to said integration means said opposite polarity signals during alternate half-cycles of such modulation signal.
 13. The process control system of claim 1 further including electrical filter means in said computer means for receiving a signal to be included in generation of said total performance indicating signal, said filter means being adjustable.
 14. The process control system of claim 1 further including means in said clock and modulation source means for delaying any integration in said control channels a predetermined time after onset of a modulation half-cycle calling for integration.
 15. The subject matter of claim 1 wherein said clock and modulation source means includes phase reversing means for selectively reversing the phase of some of said orthogonal modulation signals during said alternating intervals from their respective given phases.
 16. The subject matter of claim 15 further including noise signal generation means and said phase reversing means being responsive to said noise Signal generating means to reverse said phases of said orthogonal modulation signals in accordance with noise signals to result in a random seqUence of phase reversals.
 17. The subject matter of claim 1 wherein said clock and modulation source means includes a single frequency generation means from which all of said orthogonal modulation signals, said period signals are derived, and noise signal generation means operatively connected to said single frequency generating means for altering the frequency of operation thereof in accordance with said noise signals.
 18. The subject matter of claim 1 wherein one of said control channels has analog memory means receiving signals from said integration means for storing integrated amplitudes therefrom, and second gating means interposed between said integration means and said analog memory means for selectively gating said integrated amplitudes to said analog memory means, said second gating means being responsive to said period signal when indicating on alternating intervals to gate said integrated signal to said analog memory means.
 19. The subject matter of claim 18 further including in one of said control channels, means for receiving an analog signal to be tracked, signal combining means receiving one of said control signals and combining same with said analog signal, to form a tracked analog signal, and tracking gating means connected to said integration means in said one channel for selectively passing said tracked analog signal to said integration means.
 20. The subject matter of claim 18 further including, means to receive a reset control signal, signal combining means receiving a control signal and an integrated amplitude from one of said control channels to supply a reset to memory analog signal, and gating means electrically interposed between said signal combining means and said integration means in said one channel and responsive to said reset control signal to supply said stored integrated amplitude to said integration means such that said integration means adjusts its integrated amplitude to said stored integrated amplitude, if different.
 21. The subject matter of claim 1 further including process control model means receiving some of said modulated control signals, and further receiving some of said signals indicative of measurements made by said sensing means, said process control model including adaptive linear model means having circuit means operative as a representation of a process performance and combining said signals indicative of measurements and said modulated control signals for supplying another control signal to the process being controlled.
 22. The subject matter of claim 21 further including first controller means receiving a first set point signal and one of said signals indicating a measurement and supplying a first controller signal in joint response to said first set point signal and said one measurement signals, said process control model means receiving said first controller signal and combining same with said another control signal for supplying a single control signal including signals derived from said first controller means and from said modulated control signal.
 23. The subject matter of claim 22 further including second controller means receiving another one of said signals indicating one of said measurements and being electrically interposed between said first controller and said process controller model means for receiving as a set point said first controller signal and generating and supplying to said process control model means a second controller signal in place of said first controller signal, said process control model means receiving only said second controller signal and combining it with said modulated control signal for supplying another control signal.
 24. The subject matter of claim 21 wherein said process control model means further includes delay means electrically interposed between said adaptiVe linear model means and the process being controlled for receiving said another control signal from said adaptive linear model means and delaying same, said process delay means further receiving another modulated control signal and further receiving a measurement signal and jointly responsive to the two last mentioned signals to adjust the delay of said another control signal in joint accordance with said measurement signal and said another modulated control signal.
 25. The subject matter of claim 24 wherein said process control model means further includes lead and lag means receiving a third modulated control signal and being electrically interposed between said process delay means and said adaptive linear models and being responsive to said yet another modulated control signal to adjust the frequency characteristics of said another control signal in accordance with said third modulated control signal.
 26. A plural control-channel process-control system for controlling a process having plural performances resulting from plural interacting variables in accordance with control signals modulated by a different modulation signal for each control signal from the respective control channels, said modulation signals being orthogonal signals, said process supplying plural signals respectively indicative of process performances, means responsive to such plural performance signals for supplying at least one signal indicative of total process performance in accordance with such plural performance signals, the improvement including the combination, plural control channel means including integration means receiving said modulation signals, respectively, and responsive thereto to activate said integration means over repetitive finite time intervals for integrating said total performance signal and supplying same to control such process, clock means supplying strobe pulses having pulse durations less than any period of said modulation signals for the respective control channels, plural gating means respectively in said plural control channels and jointly responsive to said strobe pulses and, said respective modulation signals and receiving said total performance signal to supply sets of pulses to said integration means of opposing polarities respectively during alternate one-half cycles of said respective modulation signals, and means for altering the frequency of modulation without affecting said integration such that the speed of response of the system may be altered without affecting gain of the system.
 27. The process control system for controlling a process with a plurality of control channel means, clock source means generating modulation signals and quadrature modulation signals whose frequencies are related by the series 1, 2, 4, 8,... and supplying the same to said control channels, respectively, each of said control channels being responsive to said modulation signals to supply a control signal modulated by said modulation signals, respectively, means responsive to the performance of process being controlled for supplying performance indicating signals to said control channels, each of said control channels being responsive to said supplied signals for determining a gradient of process performance generated in accordance with said modulated control signals, and means for adding penalties to the performance signal for imposing plural constraints on the operation of said process control system such that the process is optimized within such set of constraints, said constraInts including weighted limits on variations of plural variables in said process.
 28. A process control system for controlling a process which supplies plural signals respectively indicative of like plural performance of a process from which a total process performance can be ascertained, and such process being responsive to control signals from a process control system to adjust variables in the process which affect such performances, The improvement including the combination, first means for supplying timing and modulation signals including quadrature modulation signals whose frequencies are related by the series 1, 2, 4, 8,... to modulate said control signals supplied to said process for effecting a dithered control of at least some of said variables with modulation having first and second half cycles, modulation of the respective variables having an orthogonal relationship, second means for receiving said plural performance signals of said process at least during modulation of said controlled variables and generating a single total performance indicating signal in accordance with said measured performances, separate third means for each of said dithered controlled variable being jointly responsive to said total performance signal and said modulation of said respective control signals for simultaneously generating changes in said respective modulated control signals such that the total performance indicating signal for both half cycles of said modulation is equal or tends to become equal in amplitude with respect to the respective control signal modulations.
 29. The process control system of claim 28 wherein said second means includes plural out-of-bound detector means respectively receiving said performance signals for comparing same with an electrically established bounds on the respective performances, and generating a first signal when said performance signal exceeds said one of said bounds, and current summing means connected to said out-of-bound detectors and responsive to said first signals to generate said single total performance signal.
 30. The process control system of claim 29 wherein said current summing means has input connections other than to said out-of-bound detectors for receiving signals other than said performance signals indicative of said measured performances and responsive thereto for imposing an electrical effect on the generation of said single total performance signal.
 31. The process control system of claim 29 wherein said second means includes upset detector means receiving said total performance signal and responsive thereto when exceeding a predetermined magnitude to supply an inhibit signal to each said separate third means for inhibiting any changes from being made in any said control signals.
 32. The process control system of claim 29 wherein said second means further includes period clamp circuit means receiving a timing signal from said first means and connected to said current summing means and responsive to said timing signal for repetitively clamping same to a reference potential indicative of optimum performance thereby inhibiting said separate third means from changing said control signals and further responsive to said timing signal to enable operation of said current summing means for repetitive finite time intervals, each finite time interval having an integral time relationship with cycle times of all said modulation signals.
 33. The process control system of claim 28 wherein one of said separate third means includes signal receiving means for receiving an auxiliary signal, mixing means receiving said control signal from said one separate third means and said auxiliary signal and jointly responsive thereto to generate another control signal.
 34. The subject matter of claim 33 wherein said auxiliary signal is one of said plural performance signals and said mixing means exhibits electrical characteristics representative of a relationship of said one plural performance signal and said control signal from said one separate third means as to operation of the process being controlled.
 35. A process control system for controlling a process toward optimal operation to perform a given function, said process being responsive to plural control signals to effect variations in operation and supplying plural signals indicative of plural process performances, the improvement including the combination, controller Means including set point means, said controller being jointly responsive to said set point means and to said function being performed to generate a control signal and supplying same to said process for effecting control of a first variable in said process, said process being responsive to said control signal for altering operation thereof, plural sensing means for sensing a plurality of performances in said process and supplying a performance indicating signal for each sensed performance, computer means jointly responsive to said plurality of measured performances to generate a signal indicative of the relationship thereof as to a total process performance, optimizing controller means including orthogonal modulation means jointly responsive to said signal indicative of total process performance, said first variable and said orthogonal modulation means for simultaneously adjusting a plurality of variables such that said total performance indicating signal is adjusted toward a predetermined magnitude, and said modulation means utilizing modulation signals and quadrature modulation signals whose frequencies are related by the series 1, 2, 4, 8,...
 36. A process control system for a process having plural performances resulting from plural interacting variables, the improvement including the combination, first means for receiving measurement signals indicative respectively of said plural performances, computer means receiving said measurement signals and responsive thereto to generate a single total performance indicating signal P(t) in accordance with wherein Px are measured process performances, SxH are high limits on optimum process performances, SxL are low limits on optimum process performances, DxH are assigned weighting factors indicative of degraded total process performance P(t) when the measured performance Px exceeds the high limit SxH on optimum process performance, DxL are assigned weighting factors indicative of degraded total process performance P(t) when the measured performance Px exceeds the low limit SxL on optimum process performance, the slashed lines / / indicate absolute magnitude of the polarity assigned to the respective Px, and control means including means for generating orthogonal modulation signals responsive to said process total performance signal P(t) and to said modulation signals to respectively generate plural orthogonally modulated control signals for respectively controlling plural variables in said process.
 37. The process control system of claim 36 further including signal supply means supplying a further signal to said control means, and said control means being jointly responsive to said further signal and one of said control signals to generate another control signal.
 38. The process control system of claim 36 further including an analog controller receiving a measurement of a performance from said process, comparing said measurement with a Set point in said controller and supplying one control signal to said process for controlling one variable in said process such that interaction of said plural variables and said one variable effects an optimization of said one variable with respect to process total performance even without modulating said control signal.
 39. The subject matter of claim 36 further including process control model means interposed between said control means and the process being controlled receiving predetermined ones of said plural orthogonally modulated control signals and receiving other indicating signals respectively indicative of predetermined process performances, said process control model means including signal processing model means having signal processing characteristics approximately representative of at least some operation of the process being performed for simulating such process performances, and said signal processing modEl means receiving said other indicating signals and said predetermined ones of said orthogonally modulated control signals to produce a single control signal from said predetermined ones of said orthogonally modulated control signals in accordance with the relationship of said other indicating signals and said approximate representation.
 40. A process control system having a plurality of control channels for supplying a plurality of orthogonally modulated control signals for controlling a plurality of variables and responsive to a plurality of measurement signals for effecting changes in said control signals, the improvement including the combination, a source of pulses supplying clock pulses having a given repetition rate, counter means receiving said clock pulses and responsive thereto to generate a plurality of orthogonal signals in synchronism with said pulses, said orthogonal signals having alternating first and second signal states, process performance computer means receiving at least one of said measurements and responsive thereto to supply a single performance indicating signal, self-optimizing performance controller means receiving said performance signal, and said orthogonal signals and being responsive to one of said orthogonal signals having a frequency lower than other ones of said orthogonal signals for serving as a period signal with first and second alternating period signal states, a plurality of control channels in said self-optimizing performance controller and receiving said performance signal, each channel receiving a different one of said orthogonal signals, each channel including input gating means jointly responsive to said period signal being in said first period signal state, said pulses and the respective one of said orthogonal signals for supplying said performance signal respectively as positive and negative pulses during said first and second portions of said orthogonal modulation signals, respectively, integration means in each said control channels receiving said supplied positive and negative pulses for integrating same, analog memory means in each of said control channels including gating means which are responsive to said period signal in said second signal state to gate the integrated signal to said analog memory means and being further responsive to said period signal in said first signal state to block the passage of said integrated signal to said analog memory means, modulation means in each of said control channels receiving signals from said analog memory means and the respective ones of said orthogonal modulation signals for modulating the output of said analog memory means and supplying same as one of the orthogonally modulated control signals, and further means responsive to said orthogonally modulated control signals for effecting control over a process, said last mentioned means including means receiving said clock pulses and another signal for adjusting said orthogonal modulated signals in accordance with said another signal, and frequency adjustment means connected to said pulse generating means for adjusting the frequency of operation thereof for altering the frequency of operation of said process control system.
 41. The subject matter of claim 40 wherein said further means includes an adaptive model means receiving one of said orthogonally modulated control signals, said clock pulses and one measurement signals, averaging circuit means in said adaptive model means jointly responsive to said clock pulses and to said one measurement signal for averaging said measurement signal, multiplying means receiving said measurement signal and an output signal from said averaging circuit means and jointly responsive thereto to provide a first multiplied control signal, phase splitting means receiving said one orthogonally modulated control signal and supplying complementary ones of said one orthogonally modulated control signal to said multiplying means, said multIplying means being jointly responsive to said multiplied control signal and to said complementary one orthogonally modulated control signals to supply an adapted control signal, and signal combining means receiving said adapted control signal and another signal and combining same to provide a single control signal for controlling at least one variable in said process.
 42. The subject matter of claim 41 further including delay means receiving one of said control signals and another one of said orthogonally modulated control signals and yet another signal and jointly responsive to the last mentioned three signals received thereby to delay the said one control signal an amount of time determined cojointly by said another one of said orthogonally modulated signals and said another signal and supplying a signal to said signal combining means for supplying a delayed control signal thereto to be used in the generation of said single control signal.
 43. The subject matter of claim 40 wherein said counter means supplies a delay signal to said input gating means for inhibiting the supplying of positive and negative pulses to said integration means until a predetermined time after transition of the one of said orthogonally modulated signals from one signal state to another signal state.
 44. The subject matter of claim 40 further including noise signal generation means supplying control signals to said counter means for altering said period signal such that said second signal state has a duration different in accordance with said received noise control signals such that the changes effected in said orthogonally modulated control signals are effected on a random time basis.
 45. The subject matter of claim 40 further including random noise generation means connected to said source of pulses for randomly altering the frequency of operation thereof such that the clock pulses have a varying pulse repetitive frequency and that all of said orthogonally modulated control signals have a randomly modulated frequency, the duration of said clock pulses remaining constant such that the gain of the process control system remains constant irrespective of the variation of frequencies of modulation and of said clock pulse repetitiveness.
 46. The subject matter of claim 40 wherein said further means comprises process control model means including signal processing circuits representative of certain characteristics of a process being controlled, said process control model means receiving a set of said orthogonally modulated control signals from said self-optimizing performance controller, further receiving a set of measurement signals, a first controller receiving a measurement signal and a set point signal and supplying a first controller signal to said process control model means, and said process control model means being jointly responsive to said first controller signal, and said sets of signals to generate a single control signal in accordance with said certain characteristics. 